2000 Ford Ranger 4.0l Transfer Case

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2000 Ford Ranger 4.0L Eng
Service Manual: DIAGNOSIS BORGWARNER 1354 TRANSFER CASE
APPLICATION
TRANSFER CASE APPLICATIONS
Application Transfer Case Model
Ford Ranger BorgWarner 1354
Mazda B3000 & B4000 BorgWarner 1354
DESCRIPTION > TRANSFER CASE
The BorgWarner 1354 transfer case is an electronic shift system that allows the operator to choose between 3
different modes: 4WD High, 4WD Low, and 2WD. Electronic shift system consists of a dashmounted rotary dial
control, an externallymounted electric shift motor with a builtin shift position sensor, and a Generic Electronic
Module (GEM). The GEM uses inputs from transmission range sensor (A/T) or clutch switch (M/T), brake switch,
and output shaft speed sensors, to control shifts between the 3 different modes. Transfer case is equipped with
an electromagnetic clutch located inside transfer case next to 2WD4WD shift collar.
When the GEM verifies completion of shift from 2WD to 4WD High, GEM will energize both Pulse Vacuum Hublock
(PVH) solenoids. See Fig 1 . Each PVH solenoid will allow a high flow of intake manifold vacuum to wheel end
hublocks, engaging wheel end hubs to achieve 4 wheel drive. When GEM verifies the shift from 4WD High to
2WD, GEM energizes only one PVH low vacuum solenoid, providing a low flow of intake manifold vacuum to
wheel end hublocks, disengaging hub from front differential and transfer case to achieve 2WD.
The electric shift motor is mounted on rear of the transfer case. Electric shift motor turns a helical cam, which
moves the HighLow fork bushing which rides in a slotted lobe in the cam to make the LowHigh or HighLow
range change. The 2WD4WD or 4WD2WD fork bushing rides on lobes at the end of the cam to make the
corresponding shift.
http://www2.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&className= 1/66
Fig 1: Pulse Vacuum Hublock Vacuum Schematic
Courtesy of FORD MOTOR CO.
OPERATION > ELECTRONIC SHIFT CONTROL SYSTEM
The Generic Electronic Module (GEM) is the microcomputer that controls transfer case shifting operations. GEM
makes shifting decisions based on inputs from rotary mode switch, transmission range sensor (A/T), vehicle and
output shaft speed sensors, shift position sensor, and clutch and brake inputs. GEM then sends signals to an
electronic shift control module containing 2 relays that powers the electric shift motor. GEM also has selftest
diagnostic capabilities. GEM is located behind center portion of instrument panel. See Fig 1 .
An electromagnetic clutch is used to spinup front drive output from zero to vehicle speed. This spinup allows
2WD to 4WD High shift to be made at any speed.
When transfer case front and rear output shafts reach the same rotating speed, a springloaded shift collar
mechanically engages output shaft hub to chain drive sprocket. Magnetic clutch is then deactivated. Shifts
between 4WD High and 4WD Low can only be made with clutch pedal depressed (M/T), or transmission range
sensor in park or neutral (A/T), and with vehicle speed 3 MPH or less.
Fig 1: Locating GEM, Electric Shift Control Module & Relays
OPERATION > INPUT DEVICES > BRAKE PEDAL POSITION SWITCH
Brake Pedal Position (BPP) switch is located behind left side of instrument panel on brake pedal support. The
GEM receives battery voltage from BPP switch when brake pedal is depressed, closing switch. When shifting into
or out of LOW range, GEM requires brake pedal to be depressed.
OPERATION > INPUT DEVICES > CLUTCH PEDAL POSITION SWITCH
Clutch Pedal Position (CPP) switch is located behind left side instrument panel on top of clutch pedal support. The
GEM receives a signal from CPP switch when clutch pedal is depressed. When shifting into or out of LOW range,
GEM requires clutch pedal to be fully depressed.
OPERATION > INPUT DEVICES > 4WD MODE SWITCH
Instrument panel mounted rotary mode switch sends input signals to GEM to control transfer case range.
OPERATION > INPUT DEVICES > SHIFT MOTOR POSITION SENSOR PLATE
The shift motor position sensor plate is an integral part of the electric shift motor assembly. Position sensor plate
sends shift motor position input to GEM.
OPERATION > INPUT DEVICES > SPEED SENSOR
GEM receives speed signals from the rear axle speed sensor mounted on top of rear differential. When shifting
into or out of LOW range, GEM requires vehicle speed to be less than 3 MPH.
OPERATION > INPUT DEVICES > TRANSMISSION RANGE SENSOR
The digital Transmission Range (TR) sensor is mounted on shift lever on left side of automatic transmission. The
TR sensor sends a digital output signal to the GEM indicating transmission shift lever position. TR sensor also
contains neutral/start and backup light circuits. Malfunction of TR sensor can cause transfer case to not shift,
improper transmission shifting or shift selection, and no engine cranking.
OPERATION > OUTPUT DEVICES > ELECTRIC SHIFT RELAY
The electric shift relay (located behind instrument panel in relay box) is used to activate the elctromagnetic clutch
within transfer case, which is used to spin up front drive system from zero to vehicle speed. When transfer case
rear and front output shafts reach a synchronous speed, the spring loaded shift collar mechanically engages
output shaft hub to the chain driven sprocket.
OPERATION > OUTPUT DEVICES > ELECTRONIC SHIFT CONTROL MODULE
The electronic shift control module (located behind center of instrument panel) contains 2 relays under control of
the GEM, that shifts the transfer case shift motor between 4WD Low, 4WD High, and 2WD modes. As shift motor
turns a helical cam, the HighLow fork bushing rides in a slotted lobe in the cam which makes the LowtoHigh or
HightoLow range change.
OPERATION > OUTPUT DEVICES > PULSE VACUUM HUBLOCK SOLENOIDS
Pulse Vacuum Hublock (PVH) solenoids are attached behind right front inner fender, near frame. PVH solenoids
alternately route a low flow or high flow of vacuum to front wheel hublocks, which engages or disengages front
axles to the hubs. See Figure .
TROUBLE SHOOTING > PRELIMINARY INSPECTION
NOTE: Manufacturer recommends using New Generation Star (NGS) tester for diagnosis of self
diagnositic system and module communications network.
NOTE: GEM must be reprogrammed upon replacement. Refer to New Generation Star (NGS)
tester screen to program tire size and axle ratio.
1. Verify customer complaint by operating 4WD system. Visually inspect for damage to switches, fuses,
wiring harness, wiring connections, vacuum connections, indicator lights, and light circuits.
2. Inspect 16pin Data Link Connector (DLC) terminals for damage. DLC is fastened to bottom of
instrument panel near steering column. If terminals are okay, go to next step. If terminals are damaged,
repair as necessary. After repairs, go to next step.
3. If concern is still present after performing inspection, connect scan tool to DLC. Select vehicle to be
tested from scan tool menu. If scan tool does not communicate with vehicle, ensure program card is
properly installed, check scan tool cable connections, and ensure ignition switch is on. If scan tool still
does not communicate with vehicle, see appropriate MODULE COMMUNICATIONS NETWORK article in
ACCESSORIES & EQUIPMENT, and/or refer to scan tool operator's manual. If scan tool communicates
with vehicle, see DIAGNOSTIC PROCEDURE SEQUENCE under DIAGNOSIS & TESTING.
TROUBLE SHOOTING > SYMPTOM DIAGNOSIS > VEHICLE DOES NOT SHIFT BETWEEN 2WD
& 4WD MODES PROPERLY
Possible cause: 4WD mode switch, electric clutch relay, electromagnetic clutch, electronic shift control module,
electric shift motor, transfer case mechanism, circuitry and/or GEM. Perform TEST A under DIAGNOSTIC
TESTS.
TROUBLE SHOOTING > SYMPTOM DIAGNOSIS > VEHICLE DOES NOT SHIFT BETWEEN 4WD
HIGH & 4WD LOW PROPERLY, SHIFTS PROPERLY BETWEEN 2WD TO 4WD HIGH & 4WD HIGH
TO 2WD
Possible cause: 4WD mode switch, vehicle speed sensor, BPP switch, transfer case, TR sensor and/or GEM.
Perform TEST B under DIAGNOSTIC TESTS.
TROUBLE SHOOTING > SYMPTOM DIAGNOSIS > 4WD LO &/OR 4WD HI INDICATOR LIGHT
NOT OPERATING PROPERLY
Possible cause: bulb, TR sensor and/or GEM. Perform TEST C under DIAGNOSTIC TESTS.
TROUBLE SHOOTING > SYMPTOM DIAGNOSIS > NO COMMUNICATION WITH GEM
Possible cause: Fuses, harness and/or GEM. Perform TEST D under DIAGNOSTIC TESTS.
TROUBLE SHOOTING > SYMPTOM DIAGNOSIS > PULSE VACUUM HUBLOCKS DO NOT
OPERATE PROPERLY
Possible cause: harness, GEM, PVH solenoid, vacuum lines, hublock assembly, steering knuckle and/or hub.
DIAGNOSIS & TESTING
NOTE: Manufacturer recommends using New Generation Star (NGS) tester for diagnosis of self
diagnositic system and module communications network.
DIAGNOSIS & TESTING > INTRODUCTION
The first step in diagnosing any driveability problem is verifying the customer complaint with a test drive under the
conditions the problem reportedly occurred. Before entering selftest diagnostics, perform a careful and complete
visual inspection. Most electronic transfer case control problems result from mechanical breakdowns or poor
electrical connections.
NOTE: Perform all voltage tests with a Digital VoltOhmmeter (DVOM) with a minimum 10
megohm input impedance, unless stated otherwise in test procedure.
DIAGNOSIS & TESTING > DIAGNOSTIC PROCEDURE SEQUENCE
1. Ensure transmission is in Park or Neutral. Ensure all controls and switches are in OFF position. Connect
scan tool to DLC.
2. Ensure all doors, hood and trunk are fully closed. Perform proper hookup procedure and vehicle
selection for scan tool. See EQUIPMENT HOOKUP .
NOTE: DO NOT touch or handle any switch or component that may produce a module
input unless instructed to do so by scan tool.
3. Retrieve and record continuous Diagnostic Trouble Codes (DTC) from GEM. See RETRIEVING
DIAGNOSTIC TROUBLE CODES .
4. Clear continuous DTCs from GEM. See CLEARING DIAGNOSTIC TROUBLE CODES .
5. Perform selftest diagnostics on GEM. See SELFTEST DIAGNOSTICS . Record all DTCs obtained
when performing selftest diagnostics. If no DTCs were obtained when retrieving continuous DTCs or
performing selftest, attempt diagnosis by symptom. See SYMPTOM DIAGNOSIS under TROUBLE
SHOOTING.
6. If DTCs were obtained when retrieving continuous DTCs or performing selftest diagnostics, see
DIAGNOSTIC TROUBLE CODE INDEX table under RETRIEVING DIAGNOSTIC TROUBLE CODES for
DTC identification and reference for proper DTC testing procedure.
NOTE: When performing specified test procedures, technician may be instructed to retrieve
Parameter Identification (PID) information on a specified component. For information on retrieving
PID, see RETRIEVING PARAMETER IDENTIFICATION INFORMATION .
DIAGNOSIS & TESTING > EQUIPMENT HOOKUP
NOTE: Manufacturer recommends using New Generation Star (NGS) tester for diagnosis of
module communications network.
1. Ensure ignition switch is in OFF position. Select proper program card for scan tool for vehicle
application. With scan tool facing away from you, insert program card into slot on scan tool. Ensure
program card is properly inserted into scan tool or scan tool will not operate.
2. Connect scan tool to 16pin DLC. DLC is located below driver's side of instrument panel, to right of
steering column.
3. Turn ignition switch to ON position. Scan tool automatically performs an initialization test. Initialization
test checks scan tool memory and verifies vehicle interface module matches program card for scan tool.
If an error message is now displayed on scan tool, refer to scan tool operator's manual for system
messages.
4. The menu item VEHICLE AND ENGINE SELECTION should be highlighted on scan tool. Press trigger to
select VEHICLE AND ENGINE SELECTION.
5. Rotate dial on scan tool to menu item SELECT NEW VEHICLE MODEL AND YEAR. Press trigger to
select VEHICLE AND ENGINE SELECTION. Select model year, vehicle and engine size by rotating dial
to highlight selection, then press trigger to select. If selected vehicle is not displayed, repeat this step.
DIAGNOSIS & TESTING > RETRIEVING DIAGNOSTIC TROUBLE CODES
1. Connect NGS tester to DLC and perform equipment hookup sequence. See EQUIPMENT HOOKUP .
NOTE: If instructed to retrieve DTCs from a specified test procedure, ensure ignition
switch is in proper position as listed in test procedure.
2. Turn ignition switch to ON position unless otherwise instructed by specified test procedure. Rotate dial
on scan tool to DIAGNOSTIC DATA LINK menu and press trigger.
3. Rotate dial on scan tool to highlight desired module you wish to access. Ensure DIAGNOSTIC TEST
MODES is highlighted and press trigger.
4. Rotate dial on scan tool to highlight RETRIEVE/CLEAR CONTINUOUS DTC and press trigger. Press
button No. 3 to start.
5. Record all DTCs that are displayed for GEM. For DTC identification and reference for proper testing
procedure, see DIAGNOSTIC TROUBLE CODE INDEX table.
DIAGNOSTIC TROUBLE CODE INDEX
DTC Description (1) Perform Test
B1483 Brake Pedal Input Circuit Failure B
B1485 Brake Pedal Input Short To Power B
P0500 VSS Signal Circuit Failure B
P1804 4WD High Indicator Circuit Failure C
P1806 4WD High Indicator Short To Power C
P1808 4WD Low Indicator Circuit Failure C
P1810 4WD Low Indicator Short To Power C
P1812 4WD Mode Select Switch Circuit Failure A
P1815 4WD Mode Select Switch Short To Ground A
P1820 T/C CW Shift Relay Circuit Failure A
P1822 T/C CW Shift Relay Coil Short To Power A
P1824 4WD Electric Clutch Relay Circuit Failure A
P1826 4WD Low Clutch Relay Short To Power A
P1828 T/C CCW Shift Relay Coil Circuit Failure A
P1830 T/C CCW Shift Relay Coil Short To Power A
P1832 T/C Differential LockUp Solenoid Failure E
P1833 T/C Differential LockUp Solenoid Open E
P1834 T/C Differential LockUp Solenoid Short To Power E
P1835 T/C Differential LockUp Solenoid Short To Ground E
P1838 T/C Shift Motor Circuit Failure A
P1846 T/C Contact Plate "A" Circuit Failure A
P1850 T/C Contact Plate "B" Circuit Failure A
P1854 T/C Contact Plate "C" Circuit Failure A
P1858 T/C Contact Plate "D" Circuit Failure A
P1863 T/C Contact Plate Power Circuit Open A
P1866 T/C System Concern A
P1867 T/C Contact Plate General Circuit Failure A
P1878 T/C Disengage Solenoid Circuit Failure E
P1879 T/C Disengage Solenoid Circuit Open E
P1880 T/C Disengage Solenoid Circuit Short To Power E
P1885 T/C Disengage Solenoid Circuit Short To Ground E
P1891 T/C Contact Plate Ground Return Circuit Open A
(1) For testing procedures, see SYSTEM TESTS .
DIAGNOSIS & TESTING > SELFTEST DIAGNOSTICS
NOTE: SelfTest may be used to verify operation of a selected module.
1. Connect NGS tester to DLC and perform equipment hookup procedure. See EQUIPMENT HOOKUP .
NOTE: If instructed to perform selftest from a specified test procedure, ensure ignition
switch is in proper position as listed in test procedure.
2. Turn ignition switch to ON position unless otherwise instructed by specified test procedure. Rotate dial
3. Rotate dial on scan tool to highlight desired module to be tested and press trigger. Ensure DIAGNOSTIC
TEST MODES is highlighted and press trigger.
4. Rotate dial on scan tool to highlight ONDEMAND SELFTEST and press trigger. Press button No. 3 to
start test. Prepare vehicle for entry condition as specified for each module. Press trigger. Record any
DTCs that are displayed.
NOTE: Only transfer caserelated DTCs are listed. For enginerelated DTC definitions,
and enginerelated DTC diagnosis, see appropriate SELFDIAGNOSTICS article in ENGINE
PERFORMANCE. These DTCs pertain to engine performance and must be repaired first, as
engine performance and related component signals will affect transfer case and transmission
operation and diagnosis.
DIAGNOSIS & TESTING > CLEARING DIAGNOSTIC TROUBLE CODES
1. Connect NGS tester to DLC and perform proper equipment hookup. See EQUIPMENT HOOKUP .
2. Turn ignition switch to ON position, unless otherwise instructed by specified test procedure. Rotate dial
3. Rotate dial on scan tool to highlight desired module you wish to access. Ensure DIAGNOSTIC TEST
MODES is highlighted and press trigger.
4. Rotate dial on scan tool to highlight RETRIEVE/CLEAR CONTINUOUS DTC and press trigger. Press
button No. 3 to start.
5. To clear an individual DTC from a selected module, rotate dial on scan tool to highlight DTC to be
cleared. Press button No. 8. This will clear only that DTC from that module.
6. To clear all DTCs from a selected module, press button No. 7. This clears all DTCs from that module.
After DTCs are cleared, turn ignition switch to OFF position, and then back to RUN position.
DIAGNOSIS & TESTING > RETRIEVING PARAMETER IDENTIFICATION INFORMATION
NOTE: This procedure may be used to verify operation of inputs and outputs for a selected
module.
1. Connect NGS tester to DLC and perform proper equipment hookup. See EQUIPMENT HOOKUP .
NOTE: If instructed to retrieve PID from a specified test procedure, ensure ignition switch
is in proper position as listed in test procedure.
2. Turn ignition switch to ON position, unless otherwise instructed by specified test procedure. Rotate dial
3. Rotate dial on scan tool to highlight desired module you wish to access and press trigger. Rotate dial on
scan tool to PID/DATA MONITOR AND RECORD and press trigger.
4. Rotate dial on scan tool to highlight PID acronyms you wish to view and press trigger. Repeat this
procedure until all desired PIDs are selected. When all PID acronyms have been selected, press "7"
button to view all selected PIDs.
DIAGNOSTIC TESTS > TEST A: VEHICLE DOES NOT SHIFT BETWEEN 2WD & 4WD MODES
PROPERLY
NOTE: For GEM connector identification, see GEM CONNECTOR IDENTIFICATION table.
GEM CONNECTOR IDENTIFICATION
Connector No. Description
C221 26Pin
C223 22Pin
C224 18Pin
1. Check Ignition States; Monitor GEM PID IGN_GEM
Turn ignition off. Connect NGS tester. Depress clutch pedal, if applicable. Monitor GEM PID Ignition
Switch Status (IGN_GEM) while turning ignition switch through RUN, OFF and ACC positions. If values
agree, go to next step. If values do not agree, diagnose ignition switch and circuits. See appropriate
STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.
NOTE: In next step, note that DTCs P1838 and P1866 require clearing GEM Keep Alive
Memory (KAM) after repairs have been completed. NGS tester will not clear these DTCs.
Disconnect and reconnect battery to clear these DTCs.
2. Retrieve DTCs
Retrieve and document continuous DTCs. Clear continuous DTCs. Perform GEM selftest. See SELF
TEST DIAGNOSTICS under DIAGNOSIS & TESTING. Retrieve DTCs. If DTCs are retrieved, go to
appropriate test step(s). See DTCTOTEST STEP INDEX table. If DTC B1342 is retrieved, replace
GEM, clear DTCs, and retest. If no DTCs are retrieved, go to next step.
DTCTOTEST STEP INDEX
DTC Go To Test Step
B1313 22
B1315 22
P1812 5
P1815 5
P1820 41
P1822 41
P1824 18
P1826 18
P1828 41
P1830 41
P1838 37
P1846 58
P1850 58
P1854 58
P1858 58
P1863 58
P1866 58
P1867 58
P1891 58
3. Check 4X4 HIGH Indicator Light
Trigger GEM active command HIGH LAMP on, and then off. If 4X4 HIGH indicator light illuminates, and
then turns off, go to next step. If indicator light does not illuminate, and then turn off, go to TEST C .
4. Check 4X4 LOW Indicator Light
Trigger GEM active command LOW LAMP on, and then off. If 4X4 LOW indicator light illuminates, and
then turns off, go to next step. If indicator light does not illuminate, and then turn off, go to TEST C .
5. Check 4X4 Mode Switch
Turn ignition on, engine off. Monitor GEM PID 4WD_SW. Place mode switch in 2WD position. If PID
indicates 2WD, go to next step. If PID does not indicate 2WD, go to step 8 . If PID indicates OFFOG,
go to step 14 .
Monitor GEM PID 4WD_SW. Place mode switch in 4X4 HIGH position. If PID indicates 4WD HIGH, go to
next step. If PID does not indicate 4WD HIGH, go to step 8 .
Monitor GEM PID 4WD_SW. Place mode switch in 4X4 LOW position. If PID indicates 4WD LOW, go to
step 16 . If PID does not indicate 4WD LOW, go to next step. If PID indicates OFFOG, go to step 14 .
8. Check 4X4 Mode Switch In 2WD Position
Turn ignition off. Disconnect 4X4 mode switch connector. Place mode switch in 2WD position. Using
ohmmeter, measure resistance between center 2 terminals (No. 2 and 3) of mode switch. If resistance is
37004100 ohms, go to next step. If resistance is not 37004100 ohms, replace mode switch. Clear
DTCs and retest system.
9. Check 4X4 Mode Switch In 4X4 HIGH Position
Place mode switch in 4X4 HIGH position. Measure resistance between center 2 terminals (No. 2 and 3)
of mode switch. If resistance is 10501150 ohms, go to next step. If resistance is not 10501150 ohms,
replace mode switch. Clear DTCs and retest system.
10. Check 4X4 Mode Switch In 4X4 LOW Position
Place mode switch in 4X4 LOW position. Measure resistance between center 2 terminals (No. 2 and 3)
of mode switch. If resistance is 340380 ohms, go to next step. If resistance is not 340380 ohms,
replace mode switch. Clear DTCs and retest system.
11. Check Circuit 465 (White/Light Blue Wire) For Open
Turn ignition off. Disconnect 4X4 mode switch connector. Disconnect GEM 22pin connector. See Fig 1 .
Measure resistance of White/Light Blue wire between terminal No. 3 on mode switch harness connector
and terminal No. 8 on GEM harness connector. If resistance is less than 5 ohms, go to next step. If
resistance is not less than 5 ohms, repair open in White/Light Blue wire. Clear DTCs and retest system.
12. Check Circuit 465 (White/Light Blue Wire) For Short To Voltage
Turn ignition on, engine off. Using DVOM, measure voltage between ground and terminal No. 3
(White/Light Blue wire) on 4X4 mode switch harness connector. If voltage is present, repair short to
voltage in White/Light Blue wire. Clear DTCs and retest system. If voltage is not present, go to next step.
13. Check Circuit 465 (White/Light Blue Wire) For Short To Ground
Using ohmmeter, measure resistance between ground and terminal No. 3 on 4X4 mode switch harness
connector. If resistance is more than 10 k/ohms, go to next step. If resistance is not more than 10
k/ohms, repair short in White/Light Blue wire. Clear DTCs and retest system.
14. Check Circuit 359 (Gray/Red Wire) For Open
Turn ignition off. Disconnect 4X4 mode switch connector. Disconnect GEM 26pin connector. See Figure
. Measure resistance of Gray/Red wire between terminal No. 2 on mode switch harness connector and
terminal No. 21 on GEM harness connector. See Fig 2 . If resistance is less than 5 ohms, go to next
step. If resistance is not less than 5 ohms, repair open in Gray/Red wire. Clear DTCs and retest system.
Fig 1: Identifying GEM 22Pin Harness Connector Terminals
15. Check Circuit 359 (Gray/Red Wire) For Short To Voltage
(Gray/Red wire) on 4X4 mode switch harness connector. If voltage is present, repair short to voltage in
Gray/Red wire. Clear DTCs and retest system. If voltage is not present, replace GEM. Clear DTCs and
retest system.
16. Check Front Drive Shaft Engagement
Start vehicle. Place shift lever in "D" position. Place mode switch in 4X4 HIGH and drive vehicle a short
distance. Raise and support vehicle. With vehicle in Drive, front and rear drive shafts should both spin. If
transfer case locks front drive shaft to rear drive shaft, go to next step. If front drive shaft does not
engage, go to step 41 . If 4WD engagement is prolonged, harsh or noisy, go to step 18 .
17. Check Front Drive Shaft Disengagement
With vehicle lowered and engine running, turn 4WD mode switch to 2WD position. When 4X4 is
disengaged, front drive shaft may spin due to viscous drag in transfer case, especially if cold. Drive a
short distance in Reverse to disengage hubs. If only rear drive shaft spins, go to TEST E . If front and
rear drive shaft are both spinning, front drive shaft is not working properly, go to step 41 .
18. Check Electric Clutch Relay
Turn ignition off. Disconnect electric clutch relay. Relay is located in relay box behind center of dash.
See Figure . Test relay. See ELECTRIC CLUTCH RELAY under COMPONENT TESTS. If relay is okay,
go to next step. If relay is not okay, replace relay. Clear DTCs and retest system.
19. Check Clutch Relay Coil Circuit
Turn ignition on, engine off. Trigger GEM active command SHIFT CLUTCH to ON. Monitor GEM PID
4WDELCL. If display is ON, go to step 21 . If display is ONB, go to next step.
20. Check Circuit 275 (Yellow Wire) For Short To Voltage
Turn ignition off. Disconnect electric clutch relay. Disconnect GEM 22pin connector. See Figure . Turn
ignition on, engine off. Using DVOM, measure voltage between ground and terminal No. 1 (Yellow wire)
on electric clutch relay socket. If voltage is present, repair short to voltage in Yellow wire. Clear DTCs
and retest system. If voltage is not present, replace GEM. Clear DTCs and retest system.
21. Check Electric Shift Relay Coil Circuit
Trigger GEM active command SHIFT CLUTCH to OFF. Monitor GEM PID 4WDELCL. If display is OFF,
go to step 36 . If display is OFFOG, go to next step.
22. Check Battery Saver Relay
Turn ignition off. Disconnect battery saver relay. Relay is located in relay box behind center of dash. See
Figure . Test relay. See ELECTRIC CLUTCH RELAY under COMPONENT TESTS. If relay is okay, go to
next step. If relay is not okay, replace relay. Clear DTCs and retest system.
23. Check Battery Saver Relay Coil Circuit
Reconnect battery saver relay. Turn ignition on, engine off. Trigger GEM active command BATT_SAVR
to ON. Monitor GEM PID BATT_SAVR. If display is ON, go to step 25 . If display is ONB, go to next
step.
24. Check Circuit 1005 (Violet/Orange Wire) For Short To Voltage
Turn ignition off. Disconnect battery saver relay. Disconnect GEM 18pin connector. See Figure . Turn
ignition on, engine off. Using DVOM, measure voltage between ground and terminal No. 2
(Violet/Orange wire) on battery saver relay socket. See Figure . If voltage is present, repair short to
voltage in Violet/Orange wire. Clear DTCs and retest system. If voltage is not present, replace GEM.
Clear DTCs and retest system.
25. Check Battery Saver Relay Coil Circuit
Trigger GEM active command BATT_SAVR to OFF. Monitor GEM PID BATT_SAVR. If display is OFF,
go to step 36 . If display is OFFOG, go to next step.
26. Measure Circuit 792 Voltage
Turn ignition off. Disconnect battery saver relay. See Figure . Turn ignition on, engine off. Using DVOM,
measure voltage on Tan/Yellow wire between ground and terminals No. 1 and 5 on battery saver relay
socket. See Figure . If voltage at both terminals is more than 10 volts, go to step 32 . If voltage at either
terminal is not more than 10 volts, go to next step.
27. Check Voltage Output From Fuse No. 26
Using DVOM, measure voltage on Tan/Yellow wire between ground and pin of fuse No. 26 (10amp) on
fuse junction panel. If voltage is more than 10 volts, repair open in Tan/Yellow wire. Replace fuse. Clear
DTCs and retest system. If voltage is not more than 10 volts, go to next step.
28. Check Fuse No. 26
Inspect fuse No. 26 in fuse junction panel. If fuse is okay, repair or replace fuse junction panel. Clear
DTCs and retest system. If fuse is not okay, go to next step.
29. Check Circuit 792 (Tan/Yellow Wire) For Short To Ground
Turn ignition off. Disconnect battery saver relay. See Figure . Using ohmmeter, measure resistance of
Tan/Yellow wire between ground and terminals No. 1 and 5 on battery saver relay socket. See Figure . If
resistance at both terminals is more than 10 k/ohms, go to next step. If resistance at either terminal is
not more than 10 k/ohms, repair short to ground in Tan/Yellow wire. Clear DTCs and retest system.
30. Check Circuit 705 (Light Green/Orange Wire) For Short To Ground
Disconnect electric clutch relay and battery saver relay. See Figure . Using ohmmeter, measure
resistance of Light Green/Orange wire between ground and terminal No. 3 on battery saver relay
socket. See Figure . If resistance is more than 10 k/ohms, go to next step. If resistance is not more than
10 k/ohms, repair short in Light Green/Orange wire. Clear DTCs and retest system.
31. Check Circuit 705 (Light Green/Orange Wire) For Open
Using ohmmeter, measure resistance of Light Green/Orange wire between terminal No. 3 on battery
saver relay socket and terminal No. 2 on electric clutch relay socket. See Figure . If resistance is less
than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Light Green/Orange
wire. Clear DTCS and retest system.
32. Check Circuit 275 (Yellow Wire) For Open
Disconnect GEM 22pin connector. See Figure . Using ohmmeter, measure resistance of Yellow wire
between terminal No. 1 on electric clutch relay socket and terminal No. 15 on GEM harness connector.
See Fig 1 and Figure . If resistance is less than 5 ohms, go to next step. If resistance is not less than 5
ohms, repair open in Yellow wire. Clear DTCs and retest system.
33. Check Circuit 275 (Yellow Wire) For Short To Ground
Using ohmmeter, measure resistance of Yellow wire between ground and terminal No. 1 on electric
clutch relay socket. See Figure . If resistance is more than 10 k/ohms, go to next step. If resistance is
not more than 10 k/ohms, repair short to ground in Yellow wire. Clear DTCs and retest system.
34. Check Circuit 1005 (Violet/Orange Wire) For Short To Ground
Using ohmmeter, measure resistance of Violet/Orange wire between ground and terminal No. 2 on
battery saver relay socket. See Figure . If resistance is more than 10 k/ohms, go to next step. If
resistance is not more than 10 k/ohms, repair short to ground in Violet/Orange wire. Clear DTCs and
retest system.
35. Check Circuit 1005 (Violet/Orange Wire) For Open
Using ohmmeter, measure resistance of Violet/Orange wire between terminal No. 2 on battery saver
relay socket and terminal No. 8 on GEM 18pin harness connector. See Fig 3 and Figure . If resistance
is less than 5 ohms, replace GEM. Clear DTCs and retest system. If resistance is not less than 5 ohms,
repair open in Violet/Orange wire. Clear DTCs and retest system.
36. Measure Circuit 779 (Brown Wire) Voltage
Turn ignition off. Disconnect transfer case 8pin connector. Turn ignition on, engine off. Trigger GEM
active command SHIFT CLUTCH to ON. Using DVOM, measure voltage between ground and terminal
No. 8 on transfer case harness connector. See Fig 4 . If voltage is more than 10 volts, go to next step. If
voltage is not more than 10 volts, go to step 38 .
Fig 4: Identifying Transfer Case 8Pin Harness Connector Terminals
37. Check Circuit 779 (Brown Wire) For Voltage
Trigger GEM active command SHIFT CLUTCH to OFF. Using DVOM, check for voltage on Brown wire
between ground and terminal No. 8 on transfer case harness connector. See Fig 4 . If voltage is not
present, replace electric clutch relay. Clear DTCs and retest system. If voltage is present, go to next
step.
38. Check Circuit 779 (Brown Wire) For Short To Voltage
Turn ignition off. Disconnect electric clutch relay. Turn ignition on, engine off. Using DVOM, check for
voltage on Brown wire between ground and terminal No. 3 on electric clutch relay socket. See Figure . If
voltage is present, repair short to voltage in Brown wire. Clear DTCs and retest system. If voltage is not
present, go to next step.
39. Check Electric Clutch Relay Switching Circuit
Using DVOM, measure voltage on Dark Green/Light Green wire between ground and terminal No. 5 on
electric clutch relay socket. See Figure . If voltage is more than 10 volts, go to next step. If voltage is not
more than 10 volts, check power distribution box minifuse No. 3 (20amp). Replace if necessary. If fuse
is okay, repair Dark Green/Light Green wire. Clear DTCs and retest system.
40. Check Circuit 779 (Brown Wire) For Open
Using ohmmeter, measure resistance of Brown wire between terminal No. 3 on electric clutch relay
socket and terminal No. 8 on transfer case 8pin harness connector. See Fig 4 and Figure . If resistance
is less than 5 ohms, replace clutch relay. Clear DTCs and retest system. If resistance is not more than 5
ohms, repair open in Brown wire. Clear DTCs and retest system.
41. Check Electric Shift Control Module
Trigger GEM active command CW/CCW to ON. Monitor GEM PIDs MTR_CCW and MTR_CW. If GEM
PIDs display ON, go to next step. If GEM PIDs display ONB, go to step 47 .
42. Check Electric Shift Control Module
Trigger GEM active command CW/CCW to OFF. Monitor GEM PIDs MTR_CCW and MTR_CW. If GEM
PIDs display OFF, go to step 50 . If GEM PIDs display OFFOG, go to next step.
43. Measure Voltage To Electric Shift Control Module Coils (Light Green/Orange Wire)
Turn ignition off. Disconnect shift control module connector. See Figure . Using DVOM, measure voltage
on Light Green/Orange wire between ground and terminal No. 5 on shift control module harness
connector. See Fig 5 . If voltage is more than 10 volts, go to next step. If voltage is not more than 10
volts, repair Light Green/Orange wire. Clear DTCs and retest system.
Fig 5: Identifying Control Module Harness Connector Terminals
44. Check Circuit 513 (Brown/Pink Wire) For Open
Disconnect GEM 22pin connector. See Figure . Using ohmmeter, measure resistance of Brown/Pink
wire between terminal No. 9 on shift control module harness connector and terminal No. 17 on GEM
harness connector. See Fig 1 and Fig 5 . If resistance is less than 5 ohms, go to next step. If resistance
is not less than 5 ohms, repair open in Brown/Pink wire. Clear DTCs and retest system.
45. Check Circuit 339 (Gray Wire) For Open
Using ohmmeter, measure resistance of Gray wire between terminal No. 8 on shift control module
harness connector and terminal No. 16 on GEM harness connector. See Fig 1 and Fig 5 . If resistance
is less than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Gray wire.
46. Check Circuits 513 (Brown/Pink Wire) & 339 (Gray Wire) For Short To Ground
Using ohmmeter, measure resistance between ground and terminals No. 8 (Gray wire) and No. 9
(Brown/Pink wire) on shift control module harness connector. See Fig 5 . If resistance for both circuits is
more than 10 k/ohms, go to step 49 . If resistance for either circuit is not more than 10 k/ohms, repair
short to ground in Brown/Pink and/or Gray wire(s). Clear DTCs and retest system.
47. Check Circuit 339 (Gray Wire) For Short To Voltage
Turn ignition off. Disconnect shift control module connector and GEM 22pin connector. See Figure .
Turn ignition on, engine off. Using DVOM, check for voltage on Gray wire between ground and terminal
No. 8 on shift control module harness connector. See Fig 5 . If voltage is present, repair short to voltage
in Gray wire. Clear DTCs and retest system. If voltage is not present, go to next step.
48. Check Circuit 513 (Brown/Pink Wire) For Short To Voltage
Using DVOM, check for voltage on Brown/Pink wire between ground and terminal No. 9 on shift control
module harness connector. See Fig 5 . If voltage is present, repair short to voltage in Brown/Pink wire.
Clear DTCs and retest system. If voltage is not present, go to next step.
49. Check Electronic Shift Control Module Coils
Using ohmmeter, measure resistance between terminal No. 5 and terminals No. 8 and 9 on shift control
module harness connector. See Fig 5 . Resistance for both circuits should be 60110 ohms. If resistance
for either circuit is between 60110 ohms, replace GEM. Clear DTCs and retest system. If resistance is
not 60110 ohms, replace shift control module. Clear DTCs and retest system.
50. Measure Voltage To Electric Shift Motor
Turn ignition off. Disconnect transfer case 8pin connector. Turn ignition on, engine off. Trigger GEM
active command CW/CCW to ON. Using DVOM, measure voltage between ground and terminals No. 4
(Yellow wire) and No. 7 (Orange wire) on transfer case 8pin harness connector. See Fig 5 . If voltage
for either circuit is more than 10 volts, go to step 52 . If voltage for either circuit is not more than 10
volts, go to next step.
51. Measure Voltage To Electronic Shift Control Module Circuit 704 (Dark Green/Light Green Wire)
Turn ignition off. Disconnect electronic shift control module connector. See Figure . Using DVOM,
measure voltage on Dark Green/Light Green wire between ground and terminal No. 3 on shift control
module harness connector. If voltage is more than 10 volts, go to step 55 . If voltage is not more than
10 volts, check power distribution box fuse No. 3 (20amp). If fuse is okay, repair open in Dark
Green/Light Green wire. Clear DTCs and retest system.
52. Measure Voltage To Electric Shift Motor
Turn ignition on, engine off. Trigger GEM active command CW/CCW to OFF. Using DVOM, measure
voltage between ground and terminals No. 4 (Yellow wire) and No. 7 (Orange wire) on transfer case 8
pin harness connector. See Fig 4 . If voltage for either circuit is more than 10 volts, go to next step. If
voltage is not more than 10 volts for either circuit, go to step 54 .
53. Check Circuits 777 (Yellow Wire) & 778 (Orange Wire) For Short To Voltage
Turn ignition off. Disconnect electronic shift control module connector. See Figure . Turn ignition on,
engine off. Using DVOM, measure voltage between ground and terminals No. 4 (Yellow wire) and No. 7
(Orange wire) on transfer case 8pin harness connector. See Fig 4 . If voltage is present, repair short to
voltage in Orange and/or Yellow wire(s). Clear DTCs and retest system. If voltage is not present, replace
electronic shift control module. Clear DTCs and retest system.
54. Check Circuits 777 (Yellow Wire) & 778 (Orange Wire) For Open
Trigger GEM active command CW/CCW to OFF. Using ohmmeter, measure resistance between ground
and terminals No. 4 (Yellow wire) and 7 (Orange wire) on transfer case 8pin harness connector. See
Fig 4 . If resistances are less than 5 ohms, reconnect transfer case 8pin connector and go to step 58 .
If resistances are not less than 5 ohms, go to step 57 .
55. Check Circuit 777 (Yellow Wire) For Open
Turn ignition off. Disconnect electronic shift control module connector. Using ohmmeter, measure
resistance of Yellow wire between terminal No. 7 on electronic shift control module connector and
terminal No. 4 on transfer case 8pin harness connector. If resistance is less than 5 ohms, go to next
step. If resistance is not less than 5 ohms, repair open in Yellow wire. Clear DTCs and retest system.
56. Check Circuit 778 (Orange Wire) For Open
Using ohmmeter, measure resistance of Orange wire between terminal No. 10 on electronic shift control
module connector and terminal No. 7 on transfer case 8pin harness connector. If resistance is less than
5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Orange wire. Clear DTCs
and retest system.
57. Check Ground To Electronic Shift Control Module
Turn ignition off. Disconnect electronic shift control module connector. Using ohmmeter, measure
resistance between ground and terminal No. 1 (Black wire) on shift control module connector. If
resistance is less than 5 ohms, replace electronic shift control module. Clear DTCs and retest system. If
resistance is not less than 5 ohms, repair Black wire. Clear DTCs and retest system.
58. Check Contact Plate Switches
Turn ignition on, engine off. Monitor GEM PIDs PLATE_A, PLATE_B, PLATE_C and PLATE_D. Place
4WD mode switch in 2WD position and record PID values. Depress brake pedal. Place transmission in
Neutral. Move 4WD mode switch to 4X4 LOW position and record PID values. Compare PIDs recorded
with the following table. See 4WD MODE SWITCH PID OUTPUT table. If PIDs match with table, inspect
and repair transfer case for possible internal malfunction. See BORGWARNER 1354 OVERHAUL
article. Clear DTCs and retest system. If PIDs do not match table, go to next step.
4WD MODE SWITCH PID OUTPUT
Contact Plate 2WD 4WD LOW
PLATE_A Closed Closed
PLATE_B Closed Open
PLATE_C Open Closed
PLATE_D Closed Open
59. Check Contact Plate Switch "D" Circuits 771 (Pink/Yellow Wire) and 762 (Yellow/White Wire)
Turn ignition off. Disconnect transfer case 8pin connector. Turn ignition on. Monitor GEM PID PLATE_D.
Scan tool should display OPEN. Connect jumper wire across terminals No. 5 and 6 on transfer case 8
pin harness connector. Verify PID indicates OPEN. If PLATE_D PID changes state, go to step 62 . If
PLATE_D PID does not change state, go to next step.
60. Check Circuit 771 (Violet/Yellow Wire) For Short To Voltage
Turn ignition off. Disconnect GEM 22pin harness connector. See Figure . Measure voltage on
Violet/Yellow wire between ground and terminal No. 5 on transfer case 8pin harness connector. See Fig
4 . If voltage is more than 10 volts, repair short to voltage in Violet/Yellow wire. If voltage is not present,
go to next step.
61. Check Circuit 771 (Violet/Yellow Wire) For Short To Ground
Turn ignition off. Disconnect GEM 22pin harness connector. See Figure . Measure resistance of
Violet/Yellow wire between ground and terminal No. 5 on transfer case 8pin harness connector. See Fig
4 . If resistance is more than 10 k/ohms, go to next step. If resistance is not more than 10 k/ohms, repair
short to ground in Violet/Yellow wire. Clear DTCs and retest system. If malfunction is still present, go to
step 64 .
62. Check Circuit 771 (Violet/Yellow Wire) For Open
Measure resistance of Violet/Yellow wire between terminal No. 21 on GEM 22pin harness connector
and terminal No. 5 on transfer case 8pin harness connector. See Fig 1 and Fig 4 . If resistance is less
than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Violet/Yellow wire.
63. Check Circuit 762 (Yellow/White Wire) For Open
Measure resistance of Yellow/White wire between terminal No. 12 on GEM 22pin connector and
terminal No. 6 on transfer case 8pin harness connector. See Fig 1 and Fig 4 . If resistance is less than
5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Yellow/White wire. Clear
64. Check Contact Plate Switch "C" Circuits 762 (Yellow/White Wire) & 770 (White Wire)
Monitor GEM PID PLATE_C. Scan tool should display OPEN. Connect jumper wire between terminals
No. 1 and 6 on transfer case 8pin harness connector. See Fig 4 . PID should display OPEN. If
PLATE_C PID changes state, go to step 67 . If PLATE_C PID does not change state, go to next step.
65. Check Circuit 770 (White Wire) For Short To Voltage
Turn ignition off. Disconnect transfer case electronic shift motor. Disconnect GEM 22pin harness
connector. See Figure . Turn ignition on. Check for voltage on White wire between ground and terminal
No. 1 on transfer case 8pin harness connector. See Fig 4 . If voltage is present, repair short to voltage
in White wire. Clear DTCs and retest system. If voltage is not present, go to next step.
66. Check Circuit 770 (White Wire) For Short To Ground
Turn ignition off. Measure resistance of White wire between ground and terminal No. 1 on transfer case
8pin harness connector. See Fig 4 . If resistance is more than 10 k/ohms, go to next step. If resistance
is not more than 10 k/ohms, repair short to ground in White wire. Clear DTCs and retest system. If
malfunction is still present, reconnect transfer case 8pin harness connector, and go to next step.
67. Check Circuit 770 (White Wire) For Open
Measure resistance of White wire between terminal No. 20 on GEM 22pin harness connector and
terminal No. 1 on transfer case 8pin harness connector. See Fig 1 and Fig 4 . If resistance is less than
5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in White wire. Clear DTCs and
retest system.
68. Check Contact Plate Switch "B" Circuits 762 (Yellow/White Wire) & 764 (Brown/White Wire)
Monitor GEM PID PLATE_B. Connect jumper wire across terminals No. 2 (Brown/White wire) and No. 6
(Yellow/White wire) on transfer case 8pin harness connector. If PLATE_B PID changes state, go to step
71 . If PLATE_B PID does not change state, go to next step.
69. Check Circuit 764 (Brown/White Wire) For Short To Voltage
Turn ignition off. Disconnect transfer case electric shift motor. Disconnect GEM 22pin harness
connector. See Figure . Check for voltage on Brown/White wire between ground and terminal No. 2 on
transfer case 8pin harness connector. See Fig 4 . If voltage is present, repair short to voltage in
Brown/White wire. Clear DTCs and retest system. If voltage is not present, go to next step.
70. Check Circuit 764 (Brown/White Wire) For Short To Ground
Measure resistance of Brown/White wire between ground and terminal No. 2 on transfer case 8pin
harness connector. See Fig 4 . If resistance is more than 10 k/ohms, go to next step. If resistance is not
more than 10 k/ohms, repair short to ground in Brown/White wire. Clear DTCs and retest system. If
malfunction is still present, reconnect transfer case 8pin harness connector and go to step 72 .
71. Check Circuit 764 (Brown/White Wire) For Open
Measure resistance of Brown/White wire between terminal No. 19 on GEM 22pin harness connector
and terminal No. 2 on transfer case 8pin harness connector. See Fig 1 and Fig 4 . If resistance is less
than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Brown/White wire.
72. Check Contact Plate Switch "A" Circuits 762 (Yellow/White Wire) & 763 (Orange/White Wire)
Monitor GEM PID PLATE_A. Scan tool should display OPEN. Connect jumper wire across terminals No.
3 (Orange/White wire) and No. 6 (Yellow/White wire) on transfer case 8pin harness connector. If
PLATE_A PID changes state, go to step 75 . If PLATE_A PID does not change state, go to next step.
73. Check Circuit 763 (Orange/White Wire) For Short To Voltage
Disconnect transfer case electric shift motor. Disconnect GEM 22pin harness connector. See Figure .
Turn ignition on. Check for voltage on Orange/White wire between transfer case electric shift motor
terminal No. 3 and ground on transfer case 8pin harness connector. See Fig 4 . If voltage is present,
repair short to voltage in Orange/White wire. Clear DTCs and retest. If voltage is not present, go to next
step.
74. Check Circuit 763 (Orange/White Wire) For Short To Ground
Turn ignition off. Measure resistance of Orange/White wire between ground and terminal No. 3 on
transfer case 8pin harness connector. See Fig 4 . If resistance is more than 10 k/ohms, go to next step.
If resistance is not more than 10 k/ohms, repair short to ground in Orange/White wire. Clear DTCs and
retest system.
75. Check Circuit 763 (Orange/White Wire) For Open
Measure resistance of Orange/White wire between terminal No. 18 on GEM connector and terminal No.
3 on transfer case 8pin harness connector. See Fig 1 and Fig 4 . If resistance is less than 5 ohms,
replace shift motor. Clear DTCs and retest system. If resistance is not less than 5 ohms, repair open in
Orange/White wire. Clear DTCs and retest system.
DIAGNOSTIC TESTS > TEST B: IMPROPER SHIFT BETWEEN 4WD HIGH & 4WD LOW MODES
C221 26Pin
C223 22Pin
C224 18Pin
Turn ignition off. Connect NGS tester. Depress clutch pedal (if applicable). Monitor Generic Electronic
Module (GEM) Parameter Identification (PID) Ignition Switch Status (IGN_GEM) while turning ignition
switch through RUN, OFF and ACC positions. If PID values agree with ignition switch positions, go to
next step. If values do not agree, see appropriate STEERING COLUMN SWITCHES article in
ACCESSORIES & EQUIPMENT.
2. Retrieve DTCs
Retrieve and document continuous DTCs. Clear continuous DTCs. Retrieve selftest DTCs. If DTCs are
recorded, go to appropriate step(s). See DTCTOTEST STEP INDEX table. If DTC B1342 is retrieved,
replace GEM, clear DTCs, and retest. If no DTCs are retrieved, go to next step.
DTC Go To Test Step
B1483 17
B1485 17
P0500
With RABS 24
With 4WABS 27
P1812 5
P1815 5
3. Check 4X4 HIGH Indicator Light
Turn ignition on. Trigger GEM active command HIGH LAMP on, and then off. If 4X4 HIGH indicator light
illuminates, and then turns off, go to next step. If indicator light does not illuminate, and then turn off, go
to TEST C .
4. Check 4X4 LOW Indicator Light
Trigger GEM active command LOW LAMP on, and then off. If 4X4 LOW indicator light illuminates, and
then turns off, exit GEM active command mode, and then go to next step. If indicator light does not
illuminate, and then turn off, go to TEST C .
Place mode switch in 2WD position. Monitor GEM PID 4WD_SW. If PID indicates 2WD, go to next step.
If PID does not indicate 2WD, go to step 8 . If PID indicates OFFOG, go to step 14 .
Monitor GEM PID 4WD_SW. Place mode switch in 4X4 HIGH position. If PID indicates 4WD HIGH, go to
next step. If PID does not indicate 4WD HIGH, go to step 8 .
Monitor GEM PID 4WD_SW. Place mode switch in 4X4 LOW position. If PID does not indicate 4WD
LOW, go to next step. If PID indicates 4WD LOW, go to step 17 .
8. Check 4X4 Mode Switch In 2WD Position
Turn ignition off. Disconnect 4X4 mode switch connector. Place mode switch in 2WD position. Using
ohmmeter, measure resistance between center 2 terminals (No. 2 and 3) of mode switch connector. If
resistance is 37004100 ohms, go to next step. If resistance is not 37004100 ohms, replace mode
switch. Clear DTCs and retest system.
9. Check 4X4 Mode Switch In 4X4 HIGH Position
Place mode switch in 4X4 HIGH position. Measure resistance between center 2 terminals (No. 2 and 3)
of mode switch connector. If resistance is 10501150 ohms, go to next step. If resistance is not 1050
1150 ohms, replace mode switch. Clear DTCs and retest system.
10. Check 4X4 Mode Switch In 4X4 LOW Position
Place mode switch in 4X4 LOW position. Measure resistance between center 2 terminals (No. 2 and 3)
of mode switch connector. If resistance is 340380 ohms, go to next step. If resistance is not 340380
ohms, replace mode switch. Clear DTCs and retest system.
11. Check Circuit 465 (White/Light Blue Wire) For Open
Turn ignition off. Disconnect 4X4 mode switch connector. Disconnect GEM 22pin connector. See Figure
. Measure resistance of White/Light Blue wire between terminal No. 3 on mode switch harness
connector and terminal No. 8 on GEM harness connector. See Figure . If resistance is less than 5 ohms,
go to next step. If resistance is not less than 5 ohms, repair open in White/Light Blue wire. Clear DTCs
and retest system.
12. Check Circuit 465 (White/Light Blue Wire) For Short To Voltage
(White/Light Blue wire) on GEM 22pin harness connector. If voltage is present, repair short to voltage in
White/Light Blue wire. Clear DTCs and retest system. If voltage is not present, go to next step.
13. Check Circuit 465 (White/Light Blue Wire) For Short To Ground
Using ohmmeter, measure resistance of White/Light Blue wire between ground and terminal No. 8 on
GEM 22pin harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is
not more than 10 k/ohms, repair short to ground in White/Light Blue wire. Clear DTCs and retest system.
14. Check Circuit 359 (Gray/Red Wire) For Open
Turn ignition off. Disconnect 4X4 mode switch connector. Disconnect GEM 26pin connector. Measure
resistance of Gray/Red wire between terminal No. 2 on mode switch harness connector and terminal
No. 21 on GEM harness connector. See Figure . If resistance is less than 5 ohms, go to next step. If
resistance is not less than 5 ohms, repair open in Gray/Red wire. Clear DTCs and retest system.
15. Check Circuit 359 (Gray/Red Wire) For Short To Ground
Measure resistance between ground and terminal No. 21 (Gray/Red wire) on GEM 26pin harness
connector. If resistance is more than 10 k/ohms, go to next step. If resistance is not more than 10
k/ohms, repair short to ground in Gray/Red wire. Clear DTCs and retest system.
16. Check Circuit 359 (Gray/Red Wire) For Short To Voltage
(Gray/Red wire) on GEM 26pin harness connector. If voltage is more than 10 volts, repair short to
voltage in Gray/Red wire. Clear DTCs and retest system. If voltage is not more than 10 volts, replace
GEM. Clear DTCs and retest system.
17. Check Brake Pedal Position (BPP) Switch
While monitoring PID BOO_GEM, depress brake pedal. If PID displayed is ON, go to step 20 . If PID
does not display ON, go to next step.
18. Check Voltage To Brake Pedal Position (BPP) Switch Circuit 276 (Brown Wire)
Turn ignition off. Disconnect BPP switch connector. Using DVOM, measure voltage between ground and
Brown wire terminal (center terminal) on BPP switch harness connector. If voltage is more than 10 volts,
go to next step. If voltage is not more than 10 volts, check fuse No. 9 (7.5amp). Replace as necessary.
If fuse is okay, repair open Brown wire. Clear DTCs and retest system.
19. Check Brake Pedal Position (BPP) Switch
While monitoring GEM PID BOO_GEM, verify PID indicates OFF. Connect jumper wire across BPP
harness connector terminals No. 3 and 4. See Fig 1 . If GEM PID BOO_GEM indicates ON, replace BPP
switch. Clear DTCs and retest system. If PID does not indicate ON, inspect and repair open in Red/Light
Green wire. If circuit is okay, replace GEM. Clear DTCs and retest system.
Fig 1: Identifying 5Pin BPP Switch Harness Connector
20. Check Clutch Interlock
Turn ignition on. Monitor GEM PID CLTCHSW. Place gear selector in Park. Verify GEM PID CLTCHSW
indicates ENGAGED. Place gear selector in Neutral. Verify GEM PID CLTCHSW indicates ENGAGED.
Place gear selector in every other position except Neutral and Park. Scan tool should display
NOT_ENGAGED. If scan tool display is as specified, go to next step. If scan tool display is not as
specified, diagnose starter interrupt circuit, and digital Transmission Range (TR) sensor. See
appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. Repair as necessary.
If TR sensor and applicable circuits are okay, replace GEM. Clear DTCs and retest system.
21. Check TR Sensor PID NTRL_SW
Monitor PID NTRL_SW. Place gear selector in Neutral. Verify scan tool displays NTRL. Move gear
selector to every position except Neutral. Scan tool should display notNTRL. If scan tool display is not as
specified, go to next step. If scan tool display is as specified, go to step 24 .
22. Check Digital TR Sensor Ground (Black Wire)
Turn ignition off. Disconnect digital TR sensor connector. Using ohmmeter, measure resistance between
ground and terminal No. 7 (Black wire) at TR sensor harness connector. See Fig 2 . If resistance is less
than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open Black wire. Clear DTCs
and retest system.
Fig 2: Identifying Digital TR Sensor Harness Connector Terminals
23. Check Digital TR Sensor
Turn ignition on, engine off. Monitor GEM PID NTRL_SW. Ensure scan tool reads notNTRL. Connect
jumper wire between terminals No. 7 (Black wire) and No. 8 (Red/White wire) on TR sensor harness
connector. See Fig 2 . Scan tool should display NTRL. If scan tool display is not as specified, repair
open in Red/White wire. Clear DTCs and retest system. If scan tool display is as specified, replace TR
sensor. Clear DTCs and retest system.
24. Check Circuits 523 (Red/Violet Wire) & 519 (Light Green/Black Wire) For Short To Ground
Turn ignition off. Disconnect GEM 18pin connector. See Figure . Disconnect RABS (Rear ABS) module
connector. RABS module is located behind ash tray on instrument panel. Disconnect RABS sensor
connector located on top of rear differential. Using ohmmeter, measure resistance between ground and
terminals No. 9 (Red/Violet wire) and 18 (Light Green/Black wire) at GEM harness connector. See
Figure . If resistances are more than 10 k/ohms, go to next step. If resistances are not more than 10
k/ohms, repair short to ground in Red/Violet and/or Light Green/Black wire(s). Clear DTCs and retest
system.
25. Check Circuits 523 (Red/Violet Wire) & 519 (Light Green/Black Wire) For Open
Measure resistance of Red/Violet wire between rear antilock brake sensor and terminal No. 9 at GEM
18pin harness connector. See Figure . Measure resistance of Light Green/Black wire between terminal
No. 1 at RABS sensor harness connector and terminal No. 18 (Light Green/Black wire) at GEM 18pin
harness connector. If resistances are less than 5 ohms, go to next step. If resistances are not less than
5 ohms, repair open in Red/Violet and/or Light Green/Black wire(s). Clear DTCs and retest system.
26. Check Circuits 523 (Red/Violet Wire) & 519 (Light Green/Black Wire) For Short To Voltage
Using DVOM, measure voltage between ground and terminals No. 9 (Red/Violet wire) and 18 (Light
Green/Black wire) at GEM 18pin harness connector. If voltage is present, repair short to voltage in
Red/violet and/or Light Green/Black wire(s). Clear DTCs and retest system. If voltage is not present, go
to next step.
27. Check Vehicle Speed Sensor (VSS)
Turn ignition off. Connect GEM 18pin connector, RABS module connector and RABS sensor connector.
Turn ignition on, engine off. Monitor GEM PID VSS_GEM while driving vehicle from 0 to 55 MPH. If GEM
PID VSS_GEM value and speedometer reading are more than ZERO MPH, go to TEST A, step 18 . If
readings are ZERO MPH and vehicle is equipped with 4wheel ABS, go to next step. If readings are
ZERO MPH and vehicle is equipped with rearwheel ABS, inspect RABS sensor. See appropriate ANTI
LOCK article in BRAKES. If sensor is okay, replace GEM. Clear DTCs and retest system.
28. Check Circuit 679 (Gray/Black Wire) For Open
Turn ignition off. Disconnect GEM 18pin connector. See Figure . Disconnect 4WABS (4wheel ABS)
control module connector. 4WABS control module is located behind ash tray on instrument panel. Using
ohmmeter, measure resistance of Gray/Black wire between terminal No. 9 at GEM 18pin harness
connector and terminal No. 19 on 4WABS harness connector. See WIRING DIAGRAMS . If resistance is
less than 5 ohms, see appropriate ANTILOCK article in BRAKES. If resistance is not less than 5 ohms,
repair open in Gray/Black wire. Clear DTCs and retest system.
DIAGNOSTIC TESTS > TEST C: 4X4 HIGH &/OR 4X4 LOW INDICATOR DOES NOT OPERATE
PROPERLY
C221 26Pin
C223 22Pin
C224 18Pin
Turn ignition off. Connect NGS tester. Depress clutch pedal, if applicable. Monitor GEM PID Ignition
Switch Status (IGN_GEM) while turning ignition switch through RUN, OFF and ACC positions. If values
agree, go to next step. If values do not agree, diagnose ignition switch and circuits. See appropriate
STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.
2. Retrieve DTCs
Retrieve and document continuous DTCs. Clear continuous DTCs. Retrieve ondemand DTCs. If DTCs
are retrieved, go to appropriate step(s). See DTCTOTEST STEP INDEX table. If DTC B1342 is
present, replace GEM. Clear DTCs and retest. If no DTCs are retrieved, go to next step.
DTC Go To Test Step
P1804 3
P1806 3
P1808 3
P1810 3
3. Verify Inoperative Indicator Light
If 4X4 HIGH indicator light is not operating, go to next step. If 4X4 LOW indicator light is not operating,
go to step 9 . If both indicator lights are not operating, see appropriate INSTRUMENT PANELS article in
ACCESSORIES & EQUIPMENT.
4. Check GEM PID 4X4 HIGH Indicator Light
Monitor GEM PID 4WDHIGH while triggering GEM active command HIGH LAMP on, and then off. If 4X4
HIGH indicator light illuminates, and then turns off, go to next step. If indicator light does not illuminate,
and then turn off, and PID displays ONB, go to step 12 . If PID displays OFFOG, go to next step.
5. Check GEM PID 4X4 LOW Indicator Light
Monitor GEM PID 4WDLOW while triggering GEM active command LOW LAMP on, and then off. If 4X4
LOW indicator light illuminates, and then turns off, system is operating correctly. Go to TEST A . If
indicator light does not illuminate, and then turn off, and scan tool displays ONB, go to step 12 . If
scan tool displays OFFOG, go to next step.
6. Check Circuit 784 (Light Blue/Black Wire) For Open
Turn ignition off. Disconnect GEM 22pin connector and instrument cluster. See Figure . Using
ohmmeter, measure resistance of Light Blue/Black wire between terminal No. 2 at instrument cluster
harness connector and terminal No. 10 at GEM harness connector. See Fig 1 . If resistance is less than
5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Light Blue/Black wire. Clear
Fig 1: Checking Circuit 784
7. Check Circuit 784 (Light Blue/Black Wire) For Short To Ground
Using ohmmeter, measure resistance of Light Blue/Black wire between ground and terminal No. 10 at
GEM 22pin harness connector. See Figure . If resistance is more than 10 k/ohms, reconnect instrument
cluster connector, and then go to next step. If resistance is not more than 10 k/ohms, repair short to
ground in Light Blue/Black wire. Clear DTCs and retest system.
8. Check Instrument Cluster
Turn ignition on, engine off. Connect jumper wire between ground and terminal No. 10 on GEM 22pin
harness connector. If 4X4 LOW indicator light illuminates, go to next step. If 4X4 LOW indicator light
does not illuminate, check condition of indicator light bulb. If bulb is okay, repair or replace instrument
cluster printed circuit. Clear DTCs and retest system.
9. Check Circuit 783 (Gray Wire) For Open
Turn ignition off. Disconnect instrument cluster connector C214. See Figure . Using ohmmeter, measure
resistance of Gray wire between terminal No. 3 at instrument cluster harness connector and terminal
No. 14 at GEM 22pin harness connector. If resistance is less than 5 ohms, go to next step. If resistance
is not less than 5 ohms, repair open in Gray wire. Clear DTCs and retest system.
10. Check Circuit 783 (Gray Wire) For Short To Ground
Using ohmmeter, measure resistance of Gray wire between ground and terminal No. 14 at GEM 22pin
harness connector. See Figure . If resistance is more than 10 k/ohms, go to next step. If resistance is
not more than 10 k/ohms, repair short to ground in Gray wire. Clear DTCs and retest system.
Turn ignition on, engine off. Connect jumper wire between ground and terminal No. 14 on GEM 22pin
harness connector. See Figure . If 4X4 HIGH indicator light illuminates, replace GEM. Clear DTCs and
retest system. If 4X4 HIGH indicator light does not illuminate, check condition of indicator bulbs. If bulbs
are okay, repair or replace instrument cluster printed circuit. Clear DTCs and retest system.
12. Check Circuit 784 (Light Blue/Black Wire) For Short To Voltage
Turn ignition off. Disconnect GEM 22pin harness connector and instrument cluster connector C214.
Turn ignition on, engine off. Using DVOM, measure voltage on Light Blue/Black wire between ground
and terminal No. 10 at GEM 22pin harness connector. If voltage is more than 10 volts, repair short to
voltage in Light Blue/Black wire. Clear DTCs and retest system. If voltage is 10 not more than volts, go
to next step.
13. Check Circuit 783 (Gray Wire) For Short To Voltage
Using DVOM, check for voltage on Gray wire between ground and terminal No. 14 on GEM 22pin
harness connector. See Figure . If voltage is present, repair short to voltage in Gray wire. Clear DTCs
and retest system. If voltage is not present, go to next step.
Monitor GEM PIDs 4WDHIGH and 4WDLOW while triggering GEM active commands LOW LAMP and
HIGH LAMP off. If PIDs indicate OFFOG, check condition of bulbs. If bulbs are okay, repair or replace
instrument cluster printed circuit. Clear DTCs and retest system. If PIDs do not indicate OFFOG,
replace GEM. Clear DTCs and retest system.
DIAGNOSTIC TESTS > TEST D: NO COMMUNICATION WITH MODULE
NOTE: Steps 13 pertain to voltage supply circuits. For applicable wiring diagrams, see
appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES & ELECTRICAL.
1. Check Power Distribution Box MaxiFuse (50Amp)
Check condition of maxifuse No. 1 (50amp). If fuse is okay, go to next step. If fuse is not okay, replace
fuse. Clear DTCs and retest system. If fuse fails again, check Tan/Black circuit for short to ground.
Repair as necessary.
2. Check Fuse Junction Panel Fuse No. 25 (7.5Amp)
Check condition of fuse No. 25 (7.5amp). If fuse is okay, go to next step. If fuse is not okay, replace
fuse. Clear DTCs and retest system. If fuse fails again, check White/Yellow circuit for short to ground.
Repair if necessary.
3. Measure Circuit 1052 (Tan/Black Wire) For Voltage
Measure voltage on Tan/Black wire between ground and pin No. 2 on fuse No. 25 socket. See Fig 1 . If
voltage is more than 10 volts, go to next step. If voltage is not more than 10 volts, repair open in
Tan/Black wire. Clear DTCs and retest system.
Fig 1: Measuring Voltage On Fuse No. 25
4. Measure Voltage To GEM Circuit 1001 (White/Yellow Wire)
Turn ignition off. Disconnect GEM 18pin connector. See Figure . Measure voltage on White/Yellow wire
between ground and terminal No. 11 at GEM harness connector. See Figure . If voltage is more than 10
volts, go to next step. If voltage is not more than 10 volts, repair open White/Yellow wire. Clear DTCs
and retest system.
5. Check Circuit 570 (Black/White Wire) For Open
Disconnect GEM 26pin connector. See Figure . Measure resistance of Black/White wire between
ground and terminals No. 14 and 26 at GEM harness connector. See Figure . If resistances are less
than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open in Black/White wire.
6. Check Circuit 519 (Light Green/Black Wire) Or 57 (Black Wire) For Open
Measure resistance between ground and terminal No. 18 at GEM 18pin harness connector. See Figure
. If resistance is less than 5 ohms, see appropriate MODULE COMMUNICATIONS NETWORK article in
ACCESSORIES & EQUIPMENT. If resistance is not less than 5 ohms, repair open Black or Light
Green/Black wire. Clear DTCs and retest system.
DIAGNOSTIC TESTS > TEST E: PULSE VACUUM HUBLOCKS DO NOT OPERATE PROPERLY
(TRANSFER CASE MOTOR MOVEMENT & FRONT DRIVE SHAFT OPERATE PROPERLY)
Tip: PVH Hubs "How To Find Leaks"
C221 26Pin
C223 22Pin
C224 18Pin
1. Leak Test Wheel Ends & Lower Vacuum System (Solenoid Output)
Turn ignition off. Raise and support vehicle. Disconnect PVH solenoid vacuum connector. PVH solenoid
valve is located behind right inner fender, near frame. Attach vacuum pump to PVH solenoid upper port
hose connector and apply 15 in. Hg of vacuum (pump rapidly for about 10 seconds). If vacuum leaks
down more than 1/2 in. Hg in 30 seconds, go to step 22 . If vacuum does not exceed leak down rate, go
to next step.
2. Leak Test Upper Vacuum System
Connect vacuum pump to PVH solenoid lower port hose connector. Apply 15 in. Hg of vacuum. If
vacuum leaks down more than 1/2 in. Hg in 30 seconds, go to next step. If vacuum does not exceed
leak down rate, go to step 5 .
3. Leak Test A/C System
Disconnect A/C vacuum supply line. Connect vacuum pump to A/C vacuum input line connector. Apply
15 in. Hg of vacuum. If vacuum leaks down more than 1/2 in. Hg in 30 seconds, diagnose and repair A/C
system. See appropriate article in AIR CONDITIONING & HEATING. If vacuum does not exceed leak
down rate, go to next step.
4. Check Vacuum Reservoir & Vacuum Lines
Reconnect A/C vacuum supply line. Disconnect vacuum reservoir output "T" fitting. Connect vacuum
pump to vacuum reservoir output line connector. Apply 15 in. Hg of vacuum. If vacuum leaks down more
than 1/2 in. Hg in 30 seconds, diagnose and repair engine vacuum system. If vacuum does not exceed
leak down rate, repair or replace vacuum reservoir output "T" fitting or vacuum line between "T" fitting
and PVH vacuum solenoid. Restore and retest system.
5. Check PVH Vacuum System For Engine Vacuum
Connect vacuum pump to PVH solenoid lower port hose connector. Start and run engine at idle.
Measure vacuum level. If vacuum is more than 11 in. Hg, go to step 7 . If vacuum is less than 11 in. Hg,
go to next step.
6. Check Engine & Primary Vacuum Line For Vacuum
Turn ignition off. Disconnect engine vacuum output connector. Connect vacuum gauge to engine
vacuum output connector. Measure vacuum level. If vacuum is more than 11 in. Hg, repair or replace
vacuum reservoir or vacuum lines between PVH solenoid vacuum input line and vacuum reservoir input
line. Restore and retest system. If vacuum is not more than 11 in. Hg, diagnose and repair engine for
low vacuum.
7. Check Solenoid Valve For Vacuum Leaks
Reconnect PVH solenoid vacuum connector. Disconnect left wheel end vacuum line connector. Connect
"T" fitting and vacuum gauge between left wheel end vacuum line connector and PVH solenoid vacuum
output line connector. See Fig 1 . Start and run engine at idle. Wait at least 60 seconds and measure
vacuum level. If vacuum is more than one in. Hg, replace PVH vacuum solenoid. Restore and retest
system. If vacuum is not more than one in. Hg, go to next step.
Fig 1: Leak Testing PVH Vacuum Solenoid
8. Check PVH Solenoid For Proper Vacuum Output Level (4X4 Engaged)
With vacuum gauge still connected and engine running, measure vacuum level while switching 4X4
mode switch to 4X4 HIGH position. If vacuum indicates at least 11 in. Hg after 6 seconds, but not more
than 60 seconds, go to next step. If vacuum level is not within reading or within time specification, go to
step 10 .
NOTE: The next step requires use of calibrated vacuum gauge that is accurate within 0.1
in. Hg.
9. Check PVH Solenoid For Proper Vacuum Output Level (4X4 Disengaged)
With vacuum gauge still connected and engine running, measure vacuum level while switching 4X4
mode switch to 2WD. If vacuum indicates between 5.857.10 in. Hg after 6 seconds, but not more than
30 seconds, remove vacuum gauge. Reconnect all vacuum lines and test for normal operation. If 4X4
system still does not operate properly, review customer concern and return to SYMPTOM DIAGNOSIS .
If vacuum level does not respond as indicated, go to next step.
10. Retrieve DTCs
Turn ignition off. Retrieve and document continuous DTCs. Clear continuous DTCs. Retrieve selftest
DTCs. If DTCs are retrieved, go to appropriate step(s). See DTCTOTEST STEP INDEX table. If no
DTCs are retrieved, go to next step.
DTC Go To Test Step
P1832 17
P1833 18
P1834 19
P1835 17
P1878 17
P1879 18
P1880 19
P1885 17
11. Check Circuit 298 (Violet/Orange Wire) For Voltage To PVH Solenoid
Turn ignition off. Disconnect PVH solenoid connector. Turn ignition on, engine off. Using DVOM,
measure voltage on Violet/Orange wire between ground and terminal No. 2 (center terminal) on PVH
solenoid harness connector. If voltage is more than 10 volts, go to next step. If voltage is not more than
10 volts, repair Violet/Orange wire. Clear DTCs, restore and retest system.
12. Check Circuit 599 (Pink/Light Green Wire) 4X4 Engage Sequence
Using DVOM, measure voltage between terminals No. 2 (Violet/Orange wire) and No. 1 (Pink/Light
Green wire) at PVH solenoid harness connector while switching 4X4 mode switch to 4WD HIGH position.
If voltage is more than 9 volts after 3 seconds, but not more than 60 seconds after switching, go to next
step. If voltage is not as described, go to step 17 .
13. Check Circuit 599 (Pink/Light Green Wire) 4X4 Disengage Sequence
Using DVOM, measure voltage between terminals No. 2 (Violet/Orange wire) and No. 1 (Pink/Light
Green wire) at PVH solenoid harness connector, while switching 4X4 mode switch to 2WD position. If
voltage is more than 9 volts after 3 seconds, but not more than 60 seconds after switching, go to next
14. Check Circuit 77 (Dark Blue/Yellow Wire) 4X4 Engage Sequence
Using DVOM, measure voltage between terminals No. 2 (Violet/Orange wire) and No. 3 (Dark
Blue/Yellow wire) at PVH solenoid harness connector. Turn 4WD mode switch to 4X4 HIGH position. If
voltage is more than 9 volts after 3 seconds, but not more than 60 seconds after switching, go to next
15. Check Circuit 77 (Dark Blue/Yellow Wire) 4X4 Disengage Sequence
Using DVOM, measure voltage between terminals No. 2 (Violet/Orange wire) and No. 3 (Dark
Blue/Yellow wire) at PVH solenoid harness connector while switching 4X4 mode switch to 2WD position.
If any voltage is indicated after 3 seconds, go to next step. If no voltage is indicated, go to step 17 .
16. Check PVH Solenoid Coils
Turn ignition off. Using ohmmeter, measure resistance between terminals No. 1 and 3 (outer terminals)
at PVH solenoid. If resistance is 90115 ohms, go to step 20 . If resistance is not 90115 ohms, replace
PVH solenoid. Clear DTCs and retest system.
17. Check Circuits 77 (Dark Blue/Yellow Wire) & 599 (Pink/Light Green) For Short To Ground
Disconnect PVH solenoid connector and GEM 22pin connector. Using ohmmeter, measure resistance
between ground and terminals No. 3 (Dark Blue/Yellow wire) and No. 1 (Pink/Light Green wire) on PVH
solenoid harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is not
more than 10 k/ohms, repair short to ground in Pink/Light Green and/or Dark Blue/Yellow wires. Clear
18. Check Circuits 77 (Dark Blue/Yellow Wire) & 599 (Pink/Light Green) For Open
Disconnect GEM 22pin connector. See Figure . Using ohmmeter, measure and record resistance of
Pink/Light Green wire between terminal No. 3 at GEM 22pin harness connector and Pink/Light Green
wire on terminal No. 3 at PVH solenoid harness connector. Measure and record resistance of Dark
Blue/Yellow wire between terminal No. 7 at GEM 22pin harness connector and Dark Blue/Yellow wire on
terminal No. 1 at PVH solenoid harness connector. If resistance measured for both circuits is less than 5
ohms, go to next step. If resistance for either circuit is more than 5 ohms, repair open in Pink/Light
Green and/or Dark Blue/Yellow wire. Clear DTCs and retest system.
19. Check Circuits 77 (Dark Blue/Yellow Wire) & 599 (Pink/Light Green) For Short To Voltage
Turn ignition on, engine off. Using DVOM, measure voltage between ground and terminals No. 1 (Dark
Blue/Yellow wire) and No. 3 (Pink/Light Green wire) at PVH solenoid harness connector. If voltage is
present, repair short to voltage in Pink/Light Green and/or Dark Blue/Yellow wire(s). Clear DTCs and
retest system. If voltage is not present, replace GEM. Clear DTCs and retest system.
20. Check PVH Solenoid For Proper Vacuum Output Level (4X4 Engaged)
Connect PVH solenoid connector. Start and run engine at idle. Connect a vacuum gauge to PVH
vacuum line "T" fitting. Measure vacuum level while turning 4X4 mode switch to 4X4 HIGH position. If
vacuum indicates at least 11 in. Hg after 6 seconds, but not more than 60 seconds, go to next step. If
vacuum level is not as described, replace PVH solenoid. Clear DTCs and retest system.
NOTE: The next step requires use of calibrated vacuum gauge accurate within 0.1 in. Hg.
21. Check PVH Solenoid For Proper Vacuum Output Level (4X4 Disengaged)
With vacuum gauge still connected and engine running, measure vacuum level while turning 4X4 mode
switch to 2WD. If vacuum indicates 5.857.1 in. Hg after 6 seconds, but not more than 60 seconds,
remove vacuum gauge, reconnect all vacuum lines and test for normal operation. If 4X4 system still
does not operate properly, review customer concern and return to SYMPTOM DIAGNOSIS under
TROUBLE SHOOTING. If vacuum level is not as described, replace PVH solenoid. Retest system.
22. Leak Test Right Side Wheel End
Turn ignition off. Raise and support vehicle. Disconnect right wheel end vacuum line connector. Attach
vacuum hand pump to right wheel end vacuum line, and apply 15 in. Hg of vacuum (pump rapidly for
about 10 seconds). See Fig 2 . If vacuum leaks down more than 1/2 in. Hg in 30 seconds, go to step 24
. If vacuum does not exceed leak down rate, go to next step.
Fig 2: Leak Testing Right Wheel End Vacuum Connection
23. Leak Test Left Side Wheel End
Reconnect right wheel end vacuum line connector. Disconnect left wheel end vacuum line connector.
Attach vacuum hand pump to left wheel end vacuum line and apply 15 in. Hg of vacuum (pump rapidly
for about 10 seconds). If vacuum leaks down more than 1/2 in. Hg in 30 seconds, go to next step. If
vacuum does not exceed leak down rate, verify all vacuum line connections are okay. Retest system for
normal operation. If vacuum leak is still present, replace PVH solenoid vacuum line. Clear DTCs and
retest system.
24. Check Chassis Vacuum Line For Leaks
Carefully disconnect chassis vacuum line from steel vacuum line. Attach vacuum hand pump to steel
vacuum line and apply 15 in. Hg of vacuum (pump rapidly for about 10 seconds). See Fig 3 . If vacuum
leaks down more than 1/2 in. Hg in 30 seconds, reconnect chassis vacuum line to steel line, and go to
next step. If vacuum does not exceed leak down rate, replace chassis vacuum line. Clear DTCs and
retest system.
Fig 3: Leak Testing Chassis Vacuum Line
WARNING: Do not use shop pressure, and do not apply more than 2 psi to vacuum lines
when performing this check.
25. Bubble Check RubberToSteel Chassis Vacuum Line Connection
Using a lowpressure air supply, apply no more than 2 psi continuous air pressure to vacuum wheel end
output line. Apply soapy water to rubbertosteel vacuum line connection. If air bubbles are visible at
connection, repair or replace connection or lines. Retest system. If bubbles are not present, go to next
step.
26. Bubble Check Wheel End Knuckle Steel Vacuum Line Fitting
input line at steering knuckle connection. Apply soapy water to connection. If air bubbles are visible at
connection, repair or replace connection or line. Retest system. If bubbles are not present, go to next
step.
27. Bubble Check Hublock End & HublockToWheel Hub Connection
input line. Apply soapy water to hublock and hublocktowheel hub connection. If air bubbles are visible
at hublocktowheel hub connection, replace hublocktowheel hub "O" ring. Retest system. If bubbles
are present at hublock end, replace hublock. Retest system. If bubbles are not present, go to next step.
28. Bubble Check KnuckleToWheel Bearing Connection
input line. Apply soapy water to knuckletowheel bearing connection. If air bubbles are visible, replace
knuckletowheel bearing "O" ring. Retest system. If equipped with 4wheel ABS, go to next step. If
equipped with rear wheel ABS, go to step 30 .
29. Bubble Check ABS Sensor
input line. Apply soapy water to ABS sensor. If air bubbles are visible, replace ABS sensor "O" ring.
Retest system. If no bubbles are present, go to next step.
30. Bubble Check Wheel Bearing Outer Seal
input line. Apply soapy water to wheel bearing outer seal. If air bubbles are visible, replace wheel hub
and bearing. Retest system. If no bubbles are present, go to next step.
31. Bubble Check Wheel End Shaft Seal
Remove 2 screws and slide wheel end shaft seal cover (rubber boot) back. Using a lowpressure air
supply, apply no more than 2 psi continuous air pressure to vacuum wheel end input line. Apply soapy
water to wheel end shaft. If air bubbles are visible, replace wheel end shaft seal (rubber boot). Retest
system. If no bubbles are present, go to next step.
32. Check Hublocks For Vacuum Leaks
Remove hublock assembly. Connect hublock Vacuum Test Cap (205401) to wheel end. Attach vacuum
hand pump and apply 1012 in. Hg of vacuum. If vacuum leaks down more than 1/2 in. Hg in 30
seconds, go to next step. If vacuum does not exceed leak down rate, replace hublock and "O" ring.
Retest system.
33. Check Wheel End Knuckle For Vacuum Leaks
Remove halfshaft retaining ring. Remove hub and bearing. Remove halfshaft. Install Seal Depth
Set/Vacuum Test Cap (205400) to wheel end knuckle. Install Seal Replacer/CV Tester (205399) into
inboard wheel end seal. Attach vacuum hand pump to wheel end vacuum supply hose and apply 1012
in. Hg of vacuum. If vacuum leaks down more than 1/2 in. Hg in 30 seconds, replace wheel end knuckle
seal. Retest system. If vacuum does not exceed leak down rate, go to next step.
34. Recheck Wheel End Knuckle For Vacuum Leaks (Wheel Bearing Seal Replaced)
After replacing wheel hub and bearing "O" ring, install Seal Depth Set/Vacuum Test Cap (205400) to
wheel end knuckle. Install Seal Replacer/CV Tester (205399) into inboard wheel end seal. Attach
vacuum hand pump to wheel end vacuum supply hose and apply 1012 in. Hg of vacuum. If vacuum
leaks down more than 1/2 in. Hg in 30 seconds, replace wheel end hub and bearing. Retest system. If
vacuum does not exceed leak down rate, system is okay.
COMPONENT TESTS > ELECTRIC CLUTCH RELAY
Disconnect relay. Check for continuity between terminal No. 2 and all other terminals. If resistance is 5 ohms or
less between terminal No. 2 and any other terminal, replace relay. If resistance is more than 5 ohms, connect 2
jumper wires between battery positive terminal and relay terminals No. 1 and 3. Check for voltage at terminal No.
4. If battery voltage is not present, replace relay. If battery voltage is present, connect a 3rd jumper wire between
terminal No. 2 and ground. Check for voltage at terminal No. 5. If battery voltage is not present, replace relay.
Fig 1: Identifying Electric Clutch/Battery Saver Relay Terminals
WIRING DIAGRAMS
Fig 1: Transfer Case Electronic Control System Wiring Diagram (BorgWarner 1354 Ford Ranger)
HOT AT ALL HOT AT ALL HOT AT ALL
TIMES TIMES HOT IN RUN TIMES
BATTERY CENTRAL
JUNCTION BOX 4 WHEEL JUNCTION
FUSE 26 FUSE 6 FUSE 9
(BEHIND DASH, RIGHT (LEFT REAR DRIVE BOX
10A 15A 7.5A
SIDE OF STEERING OF ENGINE FUSE 3 (BEHIND
COLUMN) COMPT) 20A LEFT SIDE
RELAY BOX OF DASH)
DK GRN/ TAN/ VIO/ VIO/ BRN
BATTERY SAVER LT GRN YEL ORG ORG
RELAY VIO/ORG 1 GRY 3
S126 4WD HI IND
5 TAN/YEL BRAKE
VIO/ TRANSMISSION PEDAL
ORG CONTROL POSITION
1 TAN/YEL SWITCH LT BLU/BLK LT BLU/BLK 2
SWITCH 4WD LO IND
(ON BRAKE
C214
VIO/ORG DRL MODULE, 2 PEDAL
2 BACKUP PULSE INSTRUMENT
SUPPORT)
VACUUM RED/ LT BLU/ CLUSTER
LAMPS
HUBLOCK LT GRN BLK
SOLENOID S228
3 LT GRN/ORG (ON RIGHT (MAIN HARNESS, POWERTRAIN
FRONT OF NEAR BREAKOUT
VEHICLE) CONTROL MODULE
RED/ TO INSTRUMENT
PNK/ DK BLU/ LT GRN CLUSTER)
LT GRN YEL
5 DK GRN/LT GRN DK GRN/LT GRN 3
S218
3 BRN YEL 7
2 LT GRN/ORG LT GRN/ORG 5
S221
1 YEL (MAIN HARN, NEAR GRY 8
BREAKOUT TO
CENTRAL JUNCTION
ELECTRIC BOX) CW RELAY
CLUTCH RELAY
21 GRY/RED 359
4WD MODE SW ORG 10
C221
3 PNK/LT GRN 599
PVH
7 DK BLU/YEL 77
PVH
8 WHT/LT BLU 465
4WD MODE SW BRN/PNK 9
10 LT BLU/BLK 784
4WD IND CTRL
12 YEL/WHT 762
4WD OUTPUT
13 RED/LT GRN 511 CCW RELAY
BOO SW INPUT BLK 1
14 GRY 783
4WD IND CTRL
15 YEL 275
ELC RLY CTRL
16 GRY 339 ELECTRIC SHIFT CONTROL
CW RLY CTRL S209
17 BRN/PNK 513 MODULE
CCW RLY CTRL BLK (BEHIND CENTER
18 ORG/WHT 763 OF DASH)
SW D INPUT
19 BRN/WHT 764
SW C INPUT G200
20 WHT 770 (BEHIND
SW B INPUT
21 VIO/YEL 771 LEFT KICK
SW A INPUT PANEL)
22 RED/WHT 463
NEUTRAL SW IN
C223
8 VIO/ORG 1005
RLY CTRL INTERIOR LIGHTS
9 GRY/BLK 679 LT BLU/RED
(RWABS) VSS (INSTRUMENT
3 LT GRN/BLK 519 ILLUMINATION)
(RABS) SPD SENS
10 RED/PNK 523 WHT/LT BLU
(RABS) SPD SENS
C224
GENERIC ELECTRONIC
MODULE (GEM)
(BEHIND CENTER
OF DASH) (MAIN HARN, NEAR
CENTRAL JUNCTION GRY/RED
BOX BREAKOUT) MULTIFUNCTION GRY/RED 3.9K 1.1K 360
RED/PNK S235 RED/PNK SWITCH OHMS OHMS OHMS
BLK
LT GRN/BLK LT GRN/BLK ILLUMINATION

S209
S235
REAR AXLE BLK 4WD MODE SWITCH
(MAIN HARN, NEAR
SENSOR CENTRAL JUNCTION
(TOP OF BOX BREAKOUT) G200
READIFFERENTIAL)
(BEHIND
LEFT KICK
INSTRUMENT GRY/BLK PANEL)
CLUSTER
ENGINE CONTROLS,
CRUISE CONTROL RED/WHT
VIO/ BRN/ ORG/ YEL/ 8
GRY/ YEL WHT WHT WHT WHT BRN YEL ORG DIGITAL
BLK TRANSMISSION
5 1 2 3 6 8 4 7 RANGE (DTR)
VSS 19 GRY/BLK P 1
GRY/BLK SENSOR
P 1 RANGE (DTR)
VSS 19 GRY/BLK GRY/BLK SENSOR
OUTPUT R 2 (LEFT SIDE OF
S139
(DASH PANEL NCA NCA NCA NCA NCA NCA NCA NCA N D TRANSMISSION)
4WHEEL ANTI
TO HEADLAMP
LOCK BRAKE TRANSFER
JUNCTION HARN)
SYSTEM MODULE CASE 7
(LEFT FRONT OF ASSEMBLY BLK
ENG COMPT) (BELOW VEHICLE, TOUCH S107
BEHIND DRIVE
CLUTCH M
TRANSMISSION) A B C D SHIFT
BLK (RIGHT SIDE
MOTOR
OF FIREWALL)
G123
139990
Fig 2: Transfer Case Electronic Control System Wiring Diagram (BorgWarner 1354 Mazda B3000
& B4000)
HOT AT ALL HOT IN HOT AT ALL
TIMES RUN TIMES
ENGINE I/P
COMPARTMENT FUSE
(BEHIND DASH, RIGHT FUSE/RELAY FUSE 3 FUSE 6 FUSE 26 FUSE 9 PANEL
SIDE OF STEERING BOX 20A 15A 10A 7.5A
COLUMN) GRY GRY 3
RELAY BOX 4WD HI IND
DK GRN/
BATTERY SAVER LT GRN PPL/ TAN/ BRN LT BLU/ LT BLU/
RELAY ORG YEL BLK BLK 2
4WD LO IND
PPL/ORG BRAKE PEDAL C214
POSITION 3.0L/
4.0L INSTRUMENT
(BPP)
TAN/YEL PPL/ ONLY CLUSTER
SWITCH
ORG (ON BRAKE
TAN/YEL PEDAL
LT BLU/BLK 14
SUPPORT)
TAN/YEL RED/
LT GRN
POWERTRAIN
CONTRTOL
MODULE (PCM)
LT GRN/ORG RED/ (RIGHT REAR OF
LT GRN OF ENG COMPT
THROUGH FIREWALL)
PPL/ORG
DK GRN/LT GRN
DK BLU/YEL
PNK/LT GRN YEL
PULSE VACUUM LT GRN/ORG
HUBLOCK SOLENOID
(NEAR RIGHT HEADLIGHT)
GRY
CW RELAY
21 GRY/RED
4WD MODE SW
T221
3 PNK/LT GRN
PVHS
7 DK BLU/YEL
PVHS ORG
8 WHT/LT BLU
4WD MODE SW
10 LT BLU/BLK
4WD IND CTRL
12 YEL/WHT
4WD OUTPUT
13 RED/LT GRN
BPP SW INPUT
14 GRY
4WD IND CTRL BRN/PNK
15 YEL
ELC RLY CTRL
16 GRY
CW RLY CTRL
17 BRN/PNK CCW RELAY
CCW RLY CTRL BLK
18 ORG/WHT
SW D INPUT
19 BRN/WHT
SW C INPUT
20 WHT BLK ELECTRIC SHIFT CONTROL
SW B INPUT MODULE
21 PPL/YEL
SW A INPUT (BEHIND CENTER OF DASH)
22 RED/WHT
NEUTRAL SW IN
T223
BLK
(LEFT KICK
PANEL)
G200
8 PPL/ORG
RLY CTRL
T224
INTERIOR LIGHTS SYSTEM LT BLU/RED 4
GENERIC ELECTRONIC (INSTRUMENT ILLUM
MODULE (GEM) INATION CIRCUIT)
(BEHIND CENTER WHT/LT BLU 3
OF DASH)
DK GRN/
LT GRN
GRY/RED GRY/RED 2
LT GRN/ 3.9K 1.1K 360
ORG OHMS OHMS OHMS
BLK 1
YEL
ILLUMINATION
BLK 4X4 SHIFT
BRN
CONTROL SWITCH
G200
RED/WHT (LEFT KICK
ELECTRIC PANEL)
M/T A/T
SHIFT RELAY
RELAY BOX
(BEHIND DASH, RIGHT BLK RED/WHT
SIDE OF STEERING
8
COLUMN) DIGITAL
8
COLUMN) DIGITAL
TRANSMISSION
P 1 RANGE (DTR)
PPL/ BRN/ ORG/ YEL/ SENSOR
BRN YEL ORG YEL WHT WHT WHT WHT R 2
N D
ELECTRONIC
SHIFT MOTOR 11
ASSEMBLY BLK
(ON LEFT SHIFT
REAR OF CLUTCH M MOTOR
TRANSMISSION) SHIFT SENSOR A B C D BLK (CENTER OF
MOTOR
FIREWALL)
G121
141759

2000 Ford Ranger 4.0l Transfer Case

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2000 Ford Ranger 4.0l Transfer Case

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6/9/2016 Printer Friendly View

DTC Description (1) Perform Test

Contact Plate 2WD 4WD LOW

PLATE_A Closed Closed

PLATE_B Closed Open

PLATE_C Open Closed

PLATE_D Closed Open

LT GRN/BLK LT GRN/BLK ILLUMINATION

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